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News from the Double R Group

Logo 26 July 2011 - Super Precision Centre Surface Slitter

Double R Consol has just introduced into its wide range of slitting machines a super precision centre surface slitting machine incorporating cantilevered rewind mandrels for optimum user friendly operation. The equipment is designed for processing highly sensitive materials such as micro porous products or thin gauge (6 micron polyester webs).

The standard equipment can accommodate a maximum width of 300 mm and is designed to slit using precision razor blades of widths down to 2 mm. The equipment is ideally suited to processing capacitor film materials as well as thin narrow width tapes up to a maximum diameter of 200 mm. The facility is provided to adjust the rewind torque to provide either a constant tension or a taper tension profile to suit the particular product being processed. The contact force between the rewind reels and the master rewind drum can be set and profiled in relation to machine speed or rewind diameter to suit the requirements of the particular product being processed. The unit is of compact design and the unsupported web through the transport system is kept to an absolute minimum, therefore, ensuring the best quality winding principle.

Trims, if required, can be extracted via a vacuum extract system or can be diverted to trim spoolers depending on the particular requirements of the end user. The centre surface principle with the techniques described above ensure the optimum rewind density of the finished reels, pancakes or pads. The equipment is supplied as a compact unit and only requires the connection of a mains incoming electrical and pneumatic supply. Process settings are provided via a simple operator's HMI positioned on the operators control cubical at the front of the machine.

Super Precision Centre Surface Slitter

Logo 12 May 2010 - Flat Bed Casting Unit

Double R Controls Ltd. have extended their range of equipment for creating holograms, lenticular or circular lenses to create images incorporating the Moiré effect on filmic/paper substrates by developing a technique for creating OVDs using a casting process as opposed to our conventional heat and pressure process.

This means that we can create an OVD by inserting a new UV casting module into a standard printing press, whether this be flexo or gravure.  We have equipment at our facility to enable us to create sample images in your substrates for evaluation purposes.

The cast image can then be metalised to create a conventional patch aluminium coated hologram if required.

Please contact for further technical information in connection with this process.

Flat Bed Casting UnitFlat Bed Casting Unit

Logo 05 August 2009 - Prepreg Spooling

With the increase in prepreg material being used on automatic tape layering (ATL) machines and fibre placement (FP) equipment, it is of paramount importance that the product is slit to the exact requirements of the process and spooled to an optimum density to enable the correct de-spooling to take place.

Prepreg Spooler

Double R Controls Ltd. have recently developed spooling equipment which has the capability of slitting prepreg material into widths over the range 3 mm (1/8") to 20 mm (¾") to suit the requirements of these processes.

When spooling product of this type, tension control is of paramount importance and, therefore, the equipment manufactured by Double R Controls Ltd. incorporates individual tension control for each of the spools being wound.

It is also recommended when processing these types of materials that the spool profile is a pineapple profile and the product is wound using an underlap technique. Also it is essential that a flexible liner is applied to the material which is wider than the product itself, so that no offset of the material takes place from layer to layer during the winding process. All these facilities are incorporated into the spooling equipment manufactured by Double R Controls Ltd.

If any further information is required in connection with the spooling of prepreg materials then please contact for further information.

Logo 24 February 2009 - Strip De-Coiler

Strip De-Coiler Double R Controls Ltd. have added to their range of unwinds and rewinds, a series of de-coilers suitable for unwinding both ferrous and non-ferrous strips of material over the range 1.5 mm to 20 mm. The equipment shown can accommodate a DIN 560 bobbin, containing material up to a maximum weight of 500 kgs. The unit is designed to operate over a tension range 1.2 Newtons to 15 Newtons and incorporates a multi-pass tension sensing compensating roller to ensure the unwind tension is maintained at a constant value at all times. The unwind mandrel is driven by a vector AC drive to ensure constant tension is maintained at all times, especially during acceleration and deceleration

Strip De-Coiler

The strip, on leaving the bobbin or pancake, passes over a fixed infeed free running chrome plated roller prior to entering the triple pass tension sensing compensating roller assembly. All rollers in the dancer assembly are chrome plated for operation in an arduous working environment. The force on the tension sensing compensating roller is applied by pneumatic cylinders which ensures that the force into the strip during the unwinding process and, therefore, the tension, is maintained at a constant value at all times.

Strip, after leaving the tension sensing roller assembly, enters the strip diverting rollers which ensures that the strip leaves the de-coiler at a fixed position, therefore, optimising its alignment with the next process.

The control system is designed in such a way that it will interface directly with any existing process. The unit can operate at speeds up to 300 metres per minute.

For further information on this equipment, please contact the sales department at Double R at

Logo 10 November 2008 - New Differential Rewind Shaft - Perfect Roll Slip Control

These 32mm wide differential slipping chuck elements for 76mm internal diameter cardboard cores, have been developed by DRC specifically to achieve a very accurate and repeatable torque range for individual rewound rolls across a wide web range.

Although similar units to these are now common place within the converting industry, it was found that when checked and tested there were large anomalies in the accuracy of the torque range between individual elements.

The elements supplied by DRC are precision manufactured, individually honed, tested and calibrated to a fixed tolerance.

Differential Rewind Shaft

The elements displayed will provide a torque output range from 40 Ncm at 0.6 bar pressure through to 400 Ncm 6 bar pressure and are truly linear torque over this range! These differential elements at this width have double rows of ball bearings which hold the core stable and prevent lateral sideways movement. Of course it is also very important that these units are used with good quality cardboard cores to achieve the best rewind results possible.

The differential elements are located on a 60mm diameter precision ground hardened shaft, to ensure accuracy of concentricity.

Differential elements can be supplied in various widths and diameters as individually units or complete rewind shafts and control system. They can be supplied directly on new machines or retro-fitted to your existing machines, these units will generally dramatically improve your winding tension profiles.

Laminates & Carbon Composite Materials

In the society will live in today where we can source simple standard machinery & equipment from all the four corners of the earth, from places that we are not even sure about their actual geographical location without reference to a world atlas, why buy from Heywood Lancashire?

Well let me explain, at Double R Consol we have a relatively simple philosophy - if you can buy metal, bolts, rollers, and bearings anywhere then we need to have something a little extra to offer, therefore we should be selling our intelligence, experience, knowledge, and our willingness to consider a completely different approach to what would be considered the norm, it just happens to get packaged up in the format of a machine!

Slitting & Rewinding Machine DC-600
  • Shaftless unwind
  • Web width 1600mm+
  • Non delaminating design
  • Digital knife setting
  • Slitting width toll - 0 + 0.5mm
  • Traverse trim spool-winding
  • Laser core alignment
  • Differential rewinding
  • Rewind cores 76-152-254mm
  • Rewind roll edge +/- 0.5mm
  • Rewind diameter 600mm+

A typical example of this methodology is detailed in the pictures shown, to the undiscerning eye a relatively simple chunk of steel with a few rollers and knives, etc, so what?


Well in truth it’s not until you get into the nitty gritty (for want of a more technical term) of the actual products to be slit and rewound, spooled, die cut, or sheeted that the real issues come to the fore!

Generally these are best understood by the customer, who knows and understands his product better than anyone else, so working closely with the customer, sharing information, understanding why something does what it does, and why it should not be done in a certain way will lead to a realisation of how it must be done to best achieve the desired results.


Once you have reached the point where you understand the product and how it behaves, then you can apply this to a specific web path design, or to a specific method of slitting to achieve the exacting slitting width tolerances you are required to achieve -0 / +0.5mm! Other considerations just as exacting relating to the +/- tolerances on rewound core location and amount rewound edge profile variation.

Still I suppose that is what we should expect from an industry where the products produced go into the manufacture of civil and military aircraft, F1 racing cars etc.

Logo 13 October 2008 - Easy Opening Packages

I am sure, at some time, we have all been in a hotel shower and been faced with the dilemma of trying to open a packet of shampoo, as per the instructions, but without success. We revert to trying to open it with our teeth and in many instances have to give up. The latest technique for overcoming this type of problem is to laser scribe a line onto the package which will allow it to retain its integrity and the package can be easily opened. The example of the shampoo in the hotel bathroom is only one of many applications where easy opening would be beneficial. In many cases it is necessary to provide an airtight seal for the product and, therefore, it is impossible to incorporate a tear tape. A tear tape has one disadvantage in that it has to be in a straight line. If we laser scribe the product, which is a laminate, we are able to cut through only part of the material, thereby retaining the sealing capability of the product. Many applications are already being promoted using this technology i.e. coffee packets, drinks, chocolates, pre-cooked foods and there are many more examples.

Laser Scribing UnitDouble R have recently developed a web handling system which has been optimised for the laser scribing process. In conjunction with one of the world’s leading laser manufacturers, Rofin / Baasel Lasertech based in Starnberg, Germany, the bespoke web handling machine has been developed providing multi-tension zones to allow thinner materials to be laser scribed without any distortion. Unfortunately, we do not live in a perfect world and as we add more layers of thinner material together the base product can suffer from gauge bands and distortion, therefore the web handling process has to be optimised, particularly when we are only trying to scribe through one layer of the material. One of the additional features on the equipment recently supplied by Double R incorporates centre line slitting and trimming which allows a reel to be separated and wound on a differential mandrel, therefore increasing productivity.

Lasers can, of course, be incorporated into standard slitting machines but the advantage of the latest Double R development is that the equipment has been optimised specifically for laser scribing and has many additional features incorporated to ensure high speed accurate scribing and perforating of multi-laminated webs in both cross web and machine direction.

Further information can be obtained from Double R, e-mail:

Or Rofin / Baasel Lasertech, visit:

Logo 23 May 2008 - Spooled Product — The Way to Higher Productivity
Single Station Spooler Converters and users of all types of material are looking for a more efficient operation when they are processing narrow width products. One way to increase the efficiency and reduce downtime is to convert the product into spools, (also known as traverse wound and level wound packages). A spool typically has at least ten times the continuous material length of a conventionally wound roll of material. The narrower the web is the greater the length that can be produced in a single package by spooling/traverse winding or level winding it.

Tear tapes for cigarette packets and threads in banknotes have been spooled for many years, however, the range of materials that are being handled in this way is increasing on a daily basis. Spooling is in fact no longer restricted to narrow width materials, with Foam and Nonwoven materials up to and in some cases in excess of 100 mm wide being processed into spooled packages having dimensions of 1.5 metres diameter by 1.0 metre wide. These “Jumbo” spools enable very high speed, long runs of unwinding, (de-spooling) into the final application process.

An increasing number of adhesive materials, such as finger lift tapes as well as foams are also being successfully wound in a spooled format. The techniques used for winding the various materials have increased and been developed over the years and with the advent of digital drive technology these can be incorporated very easily. The actual winding characteristics are of paramount importance to optimise transportation and unwinding (de-spooling) the spooled product. Technical information on the formats of spooling can be found on the Technical page of the Double R website:

To allow converters to be able to enter the market of spooled product the latest low cost, single station, high performance, entry level spooler has been developed by Double R Controls. This unit is totally self-contained and allows the user to convert a conventionally wound roll (a pre-slit roll from a slitter rewinder) into a spool, therefore providing their customer with a longer, continuous length of product, which significantly reduces roll change downtime. Simple techniques for de-spooling are also available on this equipment so that the traversing action is removed during the de-spooling process.

If you have a requirement to evaluate the principle of creating spools, then why not 'try before you buy'?


To request further information, please email

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